US11254112B2 - Cover with wear detection properties - Google Patents

Abstract

A cover includes a wear detection component. The wear detection component includes a wear layer and a visual wear indicator. The wear layer is designed and configured to reduce its thickness to a threshold thickness, or to disintegrate, after a preselected number of cleanings have been experience by the cover. The visual wear indicator is configured to indicate to the user that the cover has been through a threshold number of cleanings. When the wear layer has reduced its thickness to the threshold thickness, or has disintegrated, the wear layer reveals the visual wear indicator, indicating to the user that the cover is ready for replacement.

Description

This application claims the benefit of U.S. Prov. App. Ser. No. 62/881,109, entitled COVER WITH WEAR DETECTION PROPERTIES (P-627), filed on Jul. 31, 2019, owned by Stryker Corporation of Kalamazoo, Mich., and which is incorporated by reference in its entirety herein.

TECHNICAL FIELD AND BACKGROUND

The present disclosure relates to a cover that includes a feature for visually indicating that the cover is approaching the end of its useful life before there is a liquid breach of the cover. The cover is suitable for use as a barrier in many applications where liquid penetration is undesired.

In some applications, covers are formed from impermeable material and are intended to protect areas, objects, or people from coming into contact with a liquid. These covers have been made from flexible fabric with a flexible liquid proof coating, such as polyvinyl chlorides (“PVCs”) or polyurethanes. Over time, the covers wear and the coatings can lose their ability to prevent entry of a liquid into the protected area, or onto protected objects or people.

These covers are known to fail as barriers in a number of ways. Some failure modes are obvious, such as large cracks or tears in the cover, or a visible delamination of the coating. Other failure modes are less observable. Current methods of inspection of a cover for its integrity are reactive and identify a failure only after liquid is able to fully breached the cover.

SUMMARY

Accordingly, the present disclosure provides a cover with a wear detection component that provides a visual indication when the cover has reached a threshold level of wear to indicate that the cover is approaching the end of its useful life. By indicating when a threshold level of wear has been experienced by the cover, before a failure actually occurs, the wear detection component can help prevent a liquid breach of the cover.

One embodiment a cover includes a base layer and a wear detection component that is secured to the base layer. The wear detection component includes a wear layer where at least a portion of the wear layer is designed and configured to reduce its thickness to a threshold thickness, or to disintegrate, after a preselected number of cleanings, such as washings or wipings, have been experience by the cover. The wear detection component or the base layer also includes a visual wear indicator configured to indicate to the user that the cover has been through a threshold number of cleanings. When the wear layer has reduced its thickness to the threshold thickness, or has disintegrated, the wear layer reveals the visual wear indicator, which indicates to the user that the cover is ready for replacement.

In one embodiment, the base layer is formed from a first material that has a first thickness, and the wear layer is formed from a second material that has a second thickness. In one embodiment, the thickness of the wear layer is less than the thickness of the base layer. In other embodiment, the wear layer thickness is the same as the base layer thickness. In yet another embodiment, the wear layer thickness is greater than the base layer thickness.

In another embodiment, a cover includes a base layer and a wear detection component. The wear detection component includes a wear layer, which is designed and configured to reduce its thickness to a threshold thickness, or to disintegrate, after a preselected number of cleanings. When subject to the preselected number of cleanings, the wear layer reveals a visual wear indicator, which indicates that the cover is ready for replacement.

In one embodiment, the base layer is formed from a first material, and the wear layer is formed from a second material, which is different from the first material.

In one embodiment, the wear layer is thinner than the base layer.

In one embodiment, the wear layer includes first and second layers. The first layer is formed from the second material and forms the exterior surface of the wear layer. The second layer is disposed between the first layer and the base layer and includes the visual wear indicator. When the first layer has reduced its thickness to the threshold thickness, or has disintegrated, the visual wear indicator is revealed.

In another embodiment, the visual wear indicator includes a color, which is not visible until the first layer has reduced its thickness to the threshold thickness or has disintegrated.

In another embodiment, the visual wear indicator is formed by a color with a color intensity, and the color intensity is not visible until the first layer has reduced its thickness to the threshold thickness or has disintegrated.

According to any of the previous embodiments, the cover includes a reference layer formed from a material, which is more durable than either the base layer or the wear layer. The reference layer has a color with a color intensity, which is the same as the color and color intensity of the visual wear indicator. Therefore, as the cover is cleaned and the wear layer thins or disintegrates, a user can check to see if the color and color intensity of the reference layer matches the color and color intensity of the wear detection component, which indicates when the cover has been through the preselected number cleanings and, therefore, is ready for replacement.

In yet another embodiment, the visual wear indicator is formed by a reagent that changes color in response to a cleaning chemical. The reagent changes color when the first layer has reduced its thickness to the threshold thickness or has disintegrated.

In any of the foregoing embodiments, the thickness of the wear layer is in a range of about 50% to 75% of the thickness of the base layer, optionally in a range of about 55% to 70% of the base layer, and further optionally in a range of about 60% to 65% of the base layer.

In one embodiment, the base layer includes the visual wear indicator that indicates, when visible, that the cover has been through a threshold number cleanings, and therefore, is ready for replacement. According to one embodiment, the visual wear indicator is applied to the base layer, for example by printing or coating an image or color on or in the base layer.

In any of the foregoing embodiments, when the wear layer is formed from two layers, the first layer of the wear layer is at least liquid semi-permeable, and optionally liquid impermeable. The second layer includes a reagent that over time changes color in response to a cleaning chemical. For example, the first layer may be translucent, thus when the reagent changes color, the color indicates that the cover has been through the preselected number of cleanings and is, therefore, ready for replacement.

In one embodiment, the wear detection component is in the form of a patch, which is either integrally formed with the cover (for example by welding or gluing) or releasable attached to the cover, for example, by a releasable fastener, such as snaps, hook and loop fasteners, or by a tether, such as a lanyard.

In one embodiment, a patch for applying to the cover for indicating when the cover has reached a threshold level of wear is provided. The patch includes a wear layer and a visual wear indicator. At least a portion of the wear layer is designed and configured to reduce its thickness to a threshold thickness, or to disintegrate, after a preselected number of cleanings. When applied to the cover, the visual wear indicator is configured to indicate that the cover has been through a threshold number of cleanings and is ready for replacement. When the wear layer has reduced its thickness to the threshold thickness or has disintegrated, the wear layer reveals the visual wear indicator. The patch can be affixed to the cover by any suitable means, including welding, adhesion, snaps, hook and loop fasteners, rivets, sewing, heat and pressure, or a tether, such as a lanyard, or the like.

In another embodiment, the wear detection component includes multiple strips of material. Each strip may be formed from a different material so that the strips wear differently for different cleaning chemicals. In another embodiment, the strips may be made from the same material, but as they wear, they uncover visual wear indicators provided underneath the strips, which are formed from different reagents that react to different cleaning materials.

In one embodiment, a method of indicating when a cover has reached a threshold level of wear is provided. The method includes providing the cover with a wear detection component. The wear detection component includes a visual wear indicator and a wear layer. At least a portion of the wear layer is designed and configured to reduce its thickness to a threshold thickness, or to disintegrate, after a preselected number of cleanings. The method also includes securing the wear detection component to the base layer. When at least a portion of the wear layer has reduce its thickness to the threshold thickness, or has disintegrated, the wear layer reveals the visual wear indicator.

Any of the foregoing embodiments may be provided as a wear detection component for a cover for a mattress, a cover used as a protective garment, a cover for another type of cushion, such as a seat or a pad, or a cover for equipment.

These and other objects, advantages, and features of the disclosure will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of a patient support apparatus including a cover with a wear detection component;

FIG. 2 is a schematic plan view of the cover and a wear detection component;

FIG. 2A is a schematic plan view of the cover and another embodiment of a wear detection component;

FIG. 3 is a schematic diagram of a mattress and the cover;

FIG. 4 is an enlarged schematic diagram side view of a portion of the cover, including a base layer and a wear detection component;

FIG. 5 is an enlarged schematic diagram of the wear detection component, illustrating increasing levels of wear of a wear layer, ultimately indicating that the cover has reached a threshold level of wear and is ready for replacement;

FIG. 6 is an enlarged schematic diagram side view of a portion of a second embodiment of a cover, including a base layer and a wear detection component comprising first and second layers;

FIG. 7 is a schematic diagram of another embodiment of a wear detection component;

FIG. 8 is a schematic diagram of yet another embodiment of a wear detection component with a tether;

FIG. 9 is an enlarged schematic diagram side view of a portion of a third embodiment of a cover, including a base layer, a wear detection component comprising first and second layers, and a reference layer; and

FIG. 10 is a flow diagram including steps of a method for indicating when a cover has reached a threshold level of wear.

Before the embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The disclosure may be implemented in various other embodiments and may be practiced or carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the disclosure to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the disclosure any additional steps or components that might be combined with or into the enumerated steps or components.

DESCRIPTION OF THE EMBODIMENTS

Referring toFIGS. 1 and 2, the numeral10 generally designates a cover. As will be more fully described below, thecover10 may comprises a cover for a patient support apparatus. While described as a “patient” support apparatus, it should be understood that “patient” is to be construed broadly to include not only people undergoing medical treatment but also invalids and other persons, such as long-term care persons, who may need assistance or care but who may or may not be undergoing medical treatment. Further, although the particular form of the patient support apparatus illustrated inFIG. 1 is a bed adapted for use in a hospital or other medical setting, it will be understood that the patient support apparatus could, in different embodiments, be a cot, a stretcher, a recliner, a wheelchair, or any other mobile structure capable of supporting a patient in a healthcare environment, or a residential bed.

Referring again toFIG. 1, in the illustratedembodiment cover10 is configured as a mattress cover for a mattress M onpatient support apparatus30, which may surround theinternal components50 of a mattress M (FIG. 3). As would be understood, cover10 may be used to protect theinternal components50 of the mattress M from liquid contamination in order to avoid spoiling of theinternal components50 and/or to avoid the spread of pathogens in liquid that could be deposited on the mattress M. As will be more fully described below, cover10 includeswear detection component11 that provides a visual indication when thecover10 is approaching the end of its life and is ready for replacement, which can help prevent failure, including a liquid breach of thecover10. Thewear detection component11 can be located anywhere on thecover10 but may be located in a location on the cover where it is easily visible to a caregiver and where there would be the most, or at least a significant amount of, exposure to wear. For example, locating thewear detection component11 to the upper surface of thecover10, such as at the foot end, would likely expose it each disinfectant cycle and wear (and would get more exposure than the bottom or side of the cover10), as well as be easily viewable by a caregiver.

In the illustrated embodiment, cover10 forms abase layer12 withwear detection component11 mounted to thebase layer12. As noted, weardetection component11 is configured to indicate that thecover10 has been through a threshold number of cleanings, such as washings or wipings, and, therefore, is ready for replacement. Optionally, thewear detection component11 may be cover a small section (such as a few square inches, e.g. 1 inch×2 inch area) or substantially the whole side of the cover (in this manner the whole side becomes thebase layer12 or a majority of the base layer12) instead of covering a smaller area, as illustrated in the drawings.

Wear detection component11 may be formed with the cover or post applied (after the cover is formed), such as by integrally conformingwear detection component11 to thecover10, including by welding, adhesively bonding, or otherwise adheringwear detection component11 to cover10, or attaching wear detection component to cover10 by a releasable mechanism, as will be more fully described below.

Referring toFIGS. 2-4, in the illustrated embodiment, weardetection component11 is mounted to abase layer12, which is formed from a portion of thecover10, and is formed of a material, such as a liquid impermeable or semi-impermeable material, having a thickness T1. Examples of suitable materials for thewear component11 include unreinforced or reinforced flexible polymers, such as polyurethane (PU), polyvinylchloride (PVC), polycarbonate (PC), or combinations thereof, butyl rubber, or a polytetrafluoroethylene (PTFE), to name a few. The polymers may be extruded, rolled, dipped polymers, or polymers, which are formed into sheets of material. Further, as noted below, weardetection component11 may be made from multiple layers, where one or more of the layers may be constructed of synthetic or natural fabric, extruded, woven, nonwoven, and/or reinforced materials. Examples of suitable materials for thebase layer12 and/or cover10 include polyurethane (PU), polyvinylchloride (PVC), polycarbonate (PC), or combinations thereof, or a polytetrafluoroethylene (PTFE), such as expanded polytetrafluoroethylene (EPTFE) (suitable for an interior layer) One suitable material that is a commercially available product is Tyvek®.

In one embodiment, thewear detection component11 includes awear layer14, which is selected so that it wears (e.g. thins or disintegrates) faster than the underlying cover (e.g. through material selection or material thickness), and avisual wear indicator20, which, when revealed or uncovered by the thinning or disintegrating thewear layer14, indicates that thecover10 has been through a threshold number of cleanings and, therefore, is ready for replacement.

In one embodiment, thewear layer14 is formed from a material that is different than the material of thebase layer12. In another embodiment, thewear layer14 is formed from the same material as thebase layer12. In yet another embodiment, thewear layer14 is formed from a similar material as thebase layer12. Therefore, the mechanism that results in thewear layer14 thinning or disintegrating may be the material selection or its construction, as noted below. Optionally, the wear layer may be a membrane, such as an ink polymer, which may be applied to thebase layer12, such as by spraying or coating.

As noted, the materials of thewear layer14 and thebase layer12 may be the same, similar, or may be different. In one embodiment, the thickness T2 of thewear layer14 is less than the thickness T1 of thebase layer12. For example, the thickness T2 of thewear layer14 can be in a range of about 50% to 75% of the thickness T1 of thebase layer12, and optionally in a range of about 55% to 70% of the thickness T1, and further optionally about in a range of about 60% to 65% of the thickness T1. As would be understood the thinner the wear layer, the less durable the wear layer (when referring to a layer made of the same or less durable material than the base). In this manner, thinner layers are less durable and wear and/or disintegrate more quickly than a thicker version of the layer made of the same material.

As illustrated inFIG. 5, at least a portion of thewear layer14 is designed and configured to reduce its thickness to a threshold thickness or to disintegrate after a preselected number of cleanings have occurred. Thevisual wear indictor20, on the other hand, may be provided by a separate layer or can be included on or in either thebase layer12 or thewear layer14.

In one embodiment, thevisual wear indicator20 is included on thebase layer12, under thewear layer14. As thecover10 is laundered and used under normal use, thewear layer14 becomes thinner and thinner, and in some cases may disintegrate. Once thewear layer14 is reduced to a threshold thickness, thewear layer14 is thin enough to reveal or uncover thevisual wear indicator20 to allow a user to see thevisual wear indicator20 disposed under the wear layer14 (see e.g.FIG. 5). As noted, thewear layer14 may become thin enough that it essentially disintegrates, so that thewear layer14 is no longer covering and concealing thevisual wear indicator20, allowing a user to clearly see thevisual wear indicator20 thereunder (seeFIG. 5 far right example). Being able to see thevisual wear indicator20 indicates to the user that thecover10 is ready for replacement.

Thevisual wear indicator20 can be included on thebase layer12 in a variety of ways. For example, thevisual wear indicator20 may be printed onto thebase layer12. For example, thevisual wear indicator20 can be directly or indirectly printed onto thebase layer12, or printed directly or indirectly into thebase layer12, using, for example, dye sublimation printing. Thevisual wear indicator20 may not be a discreet or separate layer, therefore, and may be formed within or on the base layer, including when printed. Similarly, the visual wear indicator may be the color of cover itself. Thus, when thewear layer14 has sufficiently thinned that the color of the cover beneath the wear layer is visible (e.g. including when thewear layer14 is gone) this can be used to provide an indication that the cover is ready for replacement.

In another embodiment, thevisual wear indicator20 may be similarly formed on or in the underside of the wear layer14 (the side facing the cover).

In another embodiment described below, thewear layer14 may be formed from multiple layers with thevisual wear indicator20 being formed in or on one of the underlying layers of thewear layer14, including the surface facing thebase layer12, as noted. For example, thevisual wear indicator20 could be printed or sprayed onto one of the layers (or printed in one of the layers), added as a coating to one of the layers, or be provided as a thin layer or a membrane between two of the layers.

Referring toFIG. 5, thevisual wear indicator20 may be fully covered and obscured when thecover10 is new and has experienced no cleanings, and thewear layer14 is at its original thickness, so that a user cannot see thevisual wear indicator20. Alternately, thevisual wear indicator20 may start out being only partially obscured before any thinning of thewear layer14.

Referring to the center illustration inFIG. 5, as noted, thevisual wear indicator20 may be partially obscured before the cover has experienced a moderate number of cleanings, or after thewear layer14 has experienced some thinning so that thevisual wear indicator20 is partially revealed before reaching the threshold number of cleanings. Referring to the right-most illustration inFIG. 5, thewear indicator20 may be clearly visible when thewear layer10 has been reduced to its threshold thickness (or disintegrated) and no longer covers or conceals, and instead reveals, thevisual wear indicator20, which visually indicates that thecover10 is ready to be replaced. As such, the visual wear indicator may include symbols or words, such as “REPLACE WITH NEW COVER”.

In another embodiment, thewear layer14 may by formed from a colored material so that as thewear layer14 wears through, the color will disappear, which can be used to indicate the cover needs to be changed. For example, as noted above, thewear layer14 may be formed by spraying orcoating base layer12 with a polymer, such as a polymer with a color, including for example an ink polymer. Therefore, thewear layer14 may form thevisual wear indicator20, or be applied to thebase layer12 over thevisual wear indicator20, so that again, thewear detection component11 is integrally formed with thebase layer12.

Referring toFIG. 6, in another embodiment, thewear layer14 can be assembled from one or more layers. In the illustrated embodiment, wearlayer14 is formed from at least two layers—first andsecond layers14a,14bassembled together and applied on top of thebase layer12 and attached thereto by, for example, welding, stitching, adhesively bonding, or as described below by releasably attaching. Thefirst layer14acan be formed from one material, such as noted above, and defines an exterior surface of thewear layer14. Thesecond layer14bmay be formed from the same or different material, and is disposed between thefirst layer14aand thebase layer12.First layer14amay be secured tosecond layer14b, which is then secured to thebase layer12 over thevisual wear indicator20. Alternately,first layer14amay be slightly larger than the second layer and secured directly to thebase layer12 over thesecond layer14band thevisual wear indicator20.

In one embodiment, thesecond layer14bmay include or form thevisual wear indicator20. When thefirst layer14ahas reduced its thickness to the threshold thickness or disintegrated, thesecond layer14bis revealed to provide the visual indication of wear. For example, thesecond layer14bmay have a selected color that is concealed until thefirst layer14ahas reduced its thickness to the threshold thickness or has disintegrated. Optionally, thesecond layer14bcan have a color with a selected color intensity, which is concealed until thefirst layer14ahas reduced its thickness to the threshold thickness or disintegrated. When the user is able to see the color, or the intensity of the color, this can indicate to the user that thecover10 is ready to be replaced.

In another embodiment, thewear detection component11 may include a singlelayer wear layer14, which may be applied on top of thebase layer12. Thebase layer12 may have a selected color, pattern, or visual wear indicator that is concealed until thewear layer14 has reduced its thickness to the threshold thickness or disintegrated. When thewear layer14 has reduced its thickness to the threshold thickness or disintegrated, thebase layer12 is revealed to provide the visual indication of wear.

In one embodiment, thevisual wear indicator20 may be an image printed on anupper surface14cof thesecond layer14b, with theupper surface14cfacing thefirst layer14aso that thesecond layer14bbecomes the visual wear indicator. Again, as thefirst layer14ais worn or disintegrated, thevisual wear indicator20 is revealed and viewable by the user.

The color selected for thesecond layer14b(or any of the visual wear indicators) can be a bright color. Optionally, the color used for thewear detection component11 can be orange, yellow, including a neon yellow, red, blue, green, or another highly visible, noticeable, bright color. Of course, any other color could be used as desired.

As noted, suitable materials for the first orsecond layers14a,14bcan include unreinforced or reinforced flexible polymers, such as polyurethane (PU), polycarbonate (PC), polypropylene (PP), alloys or blends thereof, or polytetrafluoroethylene (PTFE), butyl rubber. Further, where the wear layer comprises a single layer, the wear layer may be formed from an ink, such as an ink polymer. Further, any of the layers and materials disclosed herein may be unreinforced or reinforced.

For example, in one embodiment, the wear layer may be made from a first top layer of PU and a second layer of PTFE. However, it should be understood that the material of thesecond layer14b, especially when forming thevisual wear indicator20, may not be important because its wear characteristics as an underlying layer may not impact the overall performance of thewear detection component11, especially when the first orouter layer14ais mounted directly to thebase layer12 of thecover10 rather than through the second layer.

Optionally or alternatively, thecover10 may include areference layer16 formed from a third material, as illustrated inFIG. 9. Thereference layer16 provides a layer that can be referenced and compared to in order to determine wear. To that end, and to maintain the integrity of thereference layer16, the material forming thereference layer16 may be more durable than both of the materials of the wear layer and the cover. In one embodiment, thereference layer16 has a color with a color intensity that is the same as the color and color intensity of thevisual wear indicator20. The increased durability of thereference layer16 means it will retain its color intensity during cleanings so that a user can compare the color intensities of thewear detection component11, i.e. thevisual wear indicator20 and thereference layer16, to determine if color intensity of thewear detection component11 matches the color and intensity of thereference layer16, indicating that thecover10 has been through the preselected number or cleanings and, therefore, is ready for replacement.

In one embodiment, referring toFIG. 9, thereference layer16 can be formed by a layer that underlies thewear detection component11 but which extends beyond the perimeter (at least on one side) of thewear detection component11. In this manner,reference layer16 is immediately adjacent thewear layer14 to provide an easy comparison of the colors.

Alternatively, thereference layer16 can be secured to thebase layer12 separate from by adjacent thewear layer14. In this case, the relative size of thewear layer14 andreference layer16 may be selected as desired.

In yet another embodiment, optionally, the wear layer14 (such asouter layer14a) can have a brighter or increased color and color intensity relative to thereference layer16. A user can compare the color intensities of thewear layer14 and thereference layer16 to determine if the color intensity of thewear layer14 has been decreased to substantially the same color intensity as thereference layer16, therefore indicating that thecover10 is ready for replacement.

Further, optionally or alternatively, thewear detection component11 may include a reagent that changes color when exposed to, for example, cleaning products or when exposed to other liquids, such as water or bodily fluids. For example, the reagent may be applied to the underside of thewear layer14 or to the top surface or incorporated into thesecond layer14b. Similarly, the reagent may be applied to the top surface ofbase layer12.

For example, suitable reagents may be selected from materials that exhibit a first color prior to contact with a liquid, such as a cleaning fluid, water, or a bodily fluid, and exhibit a second, different color after contact with the liquid. The cleaning material may be a cleaning material, such as bleach, hydrogen peroxide (H₂O₂), and/or an ammonia solution, that is applied during a routine cleaning session or may be applied at any time an inspection of thecover10 is desired. The reagent can be a reagent, such as a fluorogenic substrate, e.g. Amplex™ Red (which turns red when it encounters hydrogen peroxide), litmus paper, or pH sensitive dye.

When thewear layer14, such as thefirst layer14a, has disintegrated or reduced its thickness to the threshold thickness, the liquid may penetrate the remaining portion of the wear layer and make contact with the reagent. Thus, the color change indicates that the liquid has penetrated the wear layer. It should be understood that like the color, the reagent can be included in, on, or between any of the various layers of material disclosed herein.

For example, when thewear detection component11 is formed from two or more layers, the color change elicited by the reagent may be in response to the liquid passing through thewear layer14aand contacting thesecond layer14b. In one embodiment, thefirst layer14amay be transparent so that the color change is visible there through after the threshold thickness has been reached and the layer has disintegrated sufficiently to become permeable. Additionally, more than one reagent may be associated with thesecond layer14b(or base layer12) and located in discrete areas of the second layer (or base layer12). For example, the reagents may be selected so they are each reactive to different chemicals, pH levels, or liquids. For example, the presence of the liquid in the visual detector indicator may be indicated by a color change in one or more reagents. If a protein is present in the liquid, a reagent intended to detect the protein may change color. If the liquid passing through thefirst layer14ais expected to vary in pH, a litmus mixture may be the reagent in order to provide an indication of the pH of liquid that has entered thecover10. Reagents capable of changing color based on pKa values, the presence of liquids containing amino acids, proteins, urine, other bodily or biological liquids, or water may also be present in one or more of the layer(s).

Reagents may include chemical indicators that change color as pH changes. Acid/base indicators may be visible as a first color under neutral conditions and visible as a second, different color at an acidic or basic pH. Two examples, Bromocresol Green (also known as 3′,3″, 5′, 5″-tetrabromo-m-cresol-sulfonephthalein with a pH of 4.90) and Bromophenol Blue are blue at a neutral pH and transition through green to yellow as the pH decreases. Bromocresol Green transitions between pH values of about 5.4-3.8. Bromophenol Blue transitions between pH values of about 4.6-3.0. Another example is Phenolphthalein, which is clear at a neutral pH and transitions to red-violet at the pH increases. Phenolophthalein transitions between pH values of about 8.0 to about 9.8. Other examples include, but are not limited to, litmus, Nitrazine Strips, Bromothymol Blue, Methyl Orange, and Yamada Universal Indicator. Some reagents can be corrosive based, and could indicate exposure to bleach and hydrogen peroxide (H₂O₂), and other reagents can be solvent based and could detect polar solvents, e.g. isopropyl alcohol (IPA), ethanol, and glycol ethers.

Reagents that appear as one color when dry and a second, different color when wet can also be useful. For example, cobalt chloride is blue when dry and dark red when wet.

Reagents that luminesce may be desired if thecover10 is intended for use in lower light settings. For example, some suitable chemiluminescent reagents may be diphenyl oxalate, which can be combined with a weak base (e.g., 2,4,6-trichlorophenol) and glows when wet. Various colors may be produced depending upon the dye added to the reagent. Other examples include lunimol and fluorescein.

The reagent associated with the layer(s) may be placed in the respective layer and, optionally, impregnated in a pattern. The pattern may be individual or interlaced shapes or designs, or may be letters that spell out one or more words to indicate thecover10 is ready for replacement. Additional examples of using reagents are in disclosed in U.S. patent application Ser. No. 14/019,089 filed Sep. 5, 2013, U.S. patent application Ser. No. 16/112,027 titled “Composite Material with Failure Detection Properties” filed on Aug. 24, 2018 and incorporated herein by reference in its entirety.

In one embodiment, thewear layer14 includes afirst layer14athat is translucent, with thesecond layer14bincluding a reagent. Over time, the laundry or wiping chemical will pass through thewear layer14aso that the reagent in thesecond layer14bcan change color in response to cleaning. For example, thefirst layer14amay be semi liquid-permeable and become liquid permeable after cleaning a threshold number of times. The color change—due to the reagent in thesecond layer14b—is then visible through the translucentfirst layer14a, thus indicating that thecover10 has been through the preselected number of cleanings and is ready for replacement.

In another embodiment, thewear layer14 may be in the form of multiple bars or strips of material. The strips may be formed from the same materials described above in reference to wearlayer14. Additionally, the strips may be formed over a visual wear indicator or may form the visual wear indicator, similar to as described above. Thus, when worn the strips either reveal the underlying color or indicate the absence of the color to provide the wear indication. In one embodiment, the strips may have a reagent incorporated therein or thereunder, such as described above, which changes color to provide an indication that the cover is ready for replacement.

In another embodiment, each strip may be formed from a different material and/or have different reagent to determine different wear issues or characteristics—e.g., one strip may be sensitive to bleach, and other strips may be sensitive to hydrogen peroxide (H₂O₂), Phenolphthalein, and/or other cleaners, such as alcohol based cleaners, ethynol, and/or glycolic based cleaners. One example of a material for the strips includes polyurethane. A variety of polyurethane materials are feasible and can be selected for their varying levels of resistance to disinfectants and other cleaners and solvents mentioned herein. Polyurethane can be combined with other materials, such as polycarbonate, to add desirable characteristics to the material, such as to change the durability, softness, and flexibility.

As described more fully below, thewear detection component11 may be separate from the cover (but can be post applied) and, further, be configured in the form of a tag, a label, a patch, or other suitable element (and is generally smaller than) that is secured to the cover. Thewear detection component11 can be mounted to or formed on the cover (e.g. on base layer12) via any suitable method, including but not limited to sewing, adhesion, welding, or spraying or coating, and as such may be integrally mounted to or formed on thebase layer12 or as described below may be separate and mounted using a releasable fastener method.

Referring toFIG. 7, in one exemplary embodiment, thewear detection component11 is in the form of a separate orstandalone indicator patch22. Theindicator patch22 can be post attached to the cover (attached after the cover is formed) and mounted to thecover10 by one or more fasteners, an adhesive, stitches, and including removable fasteners, such as hook and loop fasteners, snaps, and buttons in a selected location on thebase layer12, e.g. the upper side, such as the foot end, of thecover10, which would be exposed to each cleaning and/or typically greater wear. In some embodiments, theindicator patch22 may also include a two-layer wear layer14 construction, with first and second wear layers14aand14b, similar to the wear detection component described above, with thevisual wear indicator20 being formed in or on one of the surfaces of thelayers14aor14bso that theindicator patch22 is a self-contained wear indicator component with an integral visual wear indicator. For further details of a suitable construction, reference is made to the above embodiments. Optionally, theindicator patch22 can includeadditional layers14n.

While thewear detection components11 and11′ are illustrated as being a quadrilateral (FIG. 2) or rectangular (FIG. 2A) in shape, any other shape is contemplated herein also. The wear detection components described in may vary greatly in size and may extend over the entire upper surface of the cover, as noted, or may, also as noted, be configured to occupy a small section of the cover, such as a patch. In one embodiment, the patch may be approximately 1″ (W)×2″ (L) patch and can be made of any of the above disclosed suitable materials and mounted or formed with the cover, as noted above.

In another exemplary embodiment, awear detection component111 is secured to acover10 by atether124, an example of which is illustrated inFIG. 8. Thetether124 is configured to be loosely attached to thewear detection component111 by a loop or ring124aon one end and attached to cover10 by a ring orloop124bor other fastener on its other end. Suitable tethers include flexible cords, wires, strings, or chains. As described in the previous embodiments, thewear detection component111 can include multiple layers, reagents, etc. and is configured to indicate that the cover has been through a threshold number of cleanings and is ready for replacement.

In one embodiment, weardetection component111 includes awear layer114 mounted to asubstrate112, which forms a base layer.Wear layer114 may be applied onsubstrate112 over a visual wear indicator114a, such as a color that is applied to or formed in the top surface of the substrate (or another layer beneath layer114) so that whenwear layer114 wears out (thins, disintegrates, etc.), the color will be visible and, therefore, provide the wear indication similar to as noted above. The example illustrated inFIG. 8 shows a portion of thewear layer114 partially removed, revealing thecolor114bthere below. For further optional construction ofwear layer114 and the visual wear indicators that may be employed when formingwear layer114 and the visual wear indicators, reference is made to the above embodiments.

Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the disclosure based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the disclosure to any specific orientation(s).

Method

In operation, indicating when thecover10 has reached a threshold level of wear, as described above, can be accomplished by themethod100 shown inFIG. 10. Atstep102, the method includes providing a wear indicator component on a cover, such as on a base layer, a portion of the cover or on a separate substrate that is mounted to the cover. Step104 provides a wear detection component that includes a wear layer and a visual wear indicator under or in the wear layer. The visual wear indicator, when visible, indicates that the cover has been through a threshold number of cleanings and is ready for replacement. The wear layer is designed to reduce its thickness to a threshold thickness or to disintegrate after a preselected number of cleanings so that the visual wear indicator becomes visible, either revealed or uncovered. Atstep106, the wear detection component is secured to the cover or base layer as discussed above. During normal use, the cover is subjected to a number of cleanings. As such, as thecover10 is cleaned, etc., the wear layer gets thinner and thinner. Atstep108, the method includes indicating to a user that the cover has reached a threshold level of wear when at least a portion of the wear layer has reduced its thickness to the threshold thickness or has disintegrated such that the wear layer reveals or uncovers the visual wear indicator.

Providing the wear layer atstep104 may include forming the wear layer from first and second layers, as described above. The first layer may be formed of the first material that forms the exterior surface of thewear layer14. Optionally, the visual wear indicator may be formed in or on the second layer, such as, by forming the second layer with a color or color intensity (step104). The color or color intensity of thesecond layer14bcan be concealed until thefirst layer14ahas reduced its thickness to the threshold thickness or has disintegrated, as described above.

Once a threshold thickness of the wear layer has been reached, or the wear layer has disintegrated, the visual wear indicator is revealed or uncovered, which indicates to the user that thecover10 has been through a threshold number of cleanings and is, therefore, ready for replacement.

Construction or manufacturing methods for the materials may also include the steps of providing a reagent as the wear detection component.

The above description is that of current embodiments of the disclosure. Various alterations and changes can be made without departing from the spirit and broader aspects of the disclosure as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the disclosure or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described disclosure may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present disclosure is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.

Claims (20)

We claim:

1. A cover comprising:

a base layer;

a wear detection component mounted to the base layer and including a wear layer having a thickness, at least a portion of said wear layer designed and configured to reduce its thickness to a threshold thickness or to disintegrate after a preselected number of cleanings indicating said cover is ready for replacement; and

a visual wear indicator at least partially concealed by said wear layer before the cover has been subjected to the preselected number of cleanings, wherein when said cover has been through the preselected number of cleanings said wear layer reduces its thickness to the threshold thickness or has disintegrated and reveals said visual wear indicator to visually indicate said cover is ready for replacement.

2. The cover according toclaim 1, wherein the base layer is formed from a first material having a first thickness, the wear layer is formed from a second material and has a second thickness, and the second material is the same as, similar to, or is different from said first material.

3. The cover according toclaim 2, wherein the second thickness is less than the first thickness.

4. The cover according toclaim 2, wherein said wear layer comprises first and second layers, said first layer being formed of said second material and forming an exterior surface of said wear layer, said second layer disposed between said first layer and said base layer, said second layer forming said visual wear indicator, wherein when said first layer has reduced its thickness to said threshold thickness or has disintegrated said visual wear indicator is revealed.

5. The cover according toclaim 4, wherein said visual wear indicator includes a color, said color being concealed until said first layer has reduced its thickness to said threshold thickness or has disintegrated.

6. The cover according toclaim 4, wherein said visual wear indicator includes a color with a color intensity, said color intensity being concealed until said first layer has reduced its thickness to said threshold thickness or disintegrated.

7. The cover according toclaim 6, further comprising a reference layer formed from a third material, said third material being more durable than said first material and said second material, and said reference layer having a color with a color intensity the same as said color and color intensity of said visual wear indicator wherein a user can compare said color intensities of said visual wear indicator and said reference layer to determine when said cover has been through said preselected number of cleanings and is ready for replacement.

8. The cover according toclaim 4, wherein said visual wear indicator includes a reagent, said reagent changing color in response to a cleaning chemical, said reagent changing color when said first layer has reduced its thickness to said threshold thickness or has disintegrated.

9. The cover according toclaim 4, wherein said first layer comprises at least one material selected from the group consisting of PTFE material, PU material, PC material, PVC material, and PP material.

10. The cover according toclaim 2, wherein said second thickness is (1) a range of 50% to 75% of said first thickness, (2) a range of 55% to 60% of said first thickness, or (3) about 55% of said first thickness.

11. The cover according toclaim 1, wherein said base layer includes said visual wear indicator.

12. The cover according toclaim 11, wherein said visual wear indicator is printed on or in said base layer.

13. The cover according toclaim 4, wherein said first layer of said wear layer is at least liquid semi-permeable, and said second layer includes a reagent that over time changes color in response to a liquid or cleaning chemical, and said first layer being translucent wherein when said reagent changes color said color indicates said cover has been through said preselected number of cleanings and is ready for replacement.

14. A cover comprising:

a wear detection component being mounted to said cover and including a wear layer having a thickness, at least a portion of said wear layer designed and configured to reduce its thickness to a threshold thickness, or to disintegrate, after a preselected number of cleanings; and

a visual wear indicator at least partially concealed by said wear layer before the cover has been subjected to the preselected number of cleanings, wherein when said cover has been through the preselected number of cleanings said wear layer reduces its thickness to the threshold thickness or has disintegrated and reveals said visual wear indicator to visually indicate said cover is ready for replacement.

15. The cover according toclaim 14, further comprising a base layer, said wear detection component mounted to said base layer and being formed from a first material having a first thickness, said wear layer being formed from a second material and having a second thickness, and said second material is the same as, similar to, or different from said first material.

16. The cover according toclaim 15, wherein said second thickness is less than said first thickness.

17. The cover according toclaim 14, wherein said wear layer comprises first and second layers, said first layer forming an exterior surface of said wear layer, wherein when said first layer has reduced its thickness to said threshold thickness or disintegrated said visual wear indicator is revealed.

18. The cover according toclaim 17, wherein said first layer or said second layer includes said visual wear indicator.

19. The cover according toclaim 14, wherein said visual wear indicator includes a color, further comprising a reference layer formed from a material more durable than said cover or said wear indicator component, said reference layer having a color the same as said color of said visual wear indicator wherein a user can compare the color intensities of said visual wear indicator and said reference layer to determine when said cover has been through said preselected number of cleanings and is ready for replacement.

20. A method of indicating when a cover has reached a threshold level of wear, the method comprising:

providing a wear detection component comprising:

a wear layer having a thickness, at least a portion of the wear layer designed and configured to reduce its thickness to a threshold thickness or to disintegrate after a preselected number of cleanings; and

a visual wear indicator at least partially concealed by the wear layer when the wear layer has not reduced its thickness to the threshold thickness or disintegrated;

securing the wear detection component to the cover; and

indicating to a user that the cover has reached the threshold level of wear when at least a portion of the wear layer has reduced its thickness to the threshold thickness or has disintegrated such that the wear layer reveals the visual wear indicator.

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